Three-dimensional woven fabric and method for producing the same

Abstract

A three-dimensional woven fabric including front layer, rear layer, and light-shielding layer connecting front layer to rear layer and a method thereof are disclosed. The light-shielding layer is formed by repeatedly overlapping first, second, and third light-shielding layers with another light-shielding layer with adjacent ones among the first to the third light-shielding layers overlapped. The front layer includes front parts formed by weaving front layer wrap threads and weft threads, the front parts have front layer-connecting parts formed by sequentially and repeatedly weaving front layer wrapwrap threads and weft threads and light-shielding layer wrap threads, the rear layer includes rear layer-connecting parts formed by weaving sequentially and repeatedly the rear layer wrap threads and weft threads and light-shielding layer wrap threads. The light-shielding layers are formed by weaving light-shielding layer wrap threads and the weft threads, and the light-shielding layers are sequentially and repeatedly connected to front layer-connecting parts and rear layer-connecting parts. Three-dimensional shapes are implemented without adhesive. Various designs and light-shielding control are available.

The invention claimed is: 
     
       1. A three-dimensional woven fabric comprising: a front layer, a rear layer, and a light-shielding layer connecting the front layer to the rear layer,
 wherein the light-shielding layer is formed by repeatedly overlapping a first light-shielding layer, a second light-shielding layer, and a third light-shielding layer, with adjacent ones among the first to the third light-shielding layers overlapped, 
 wherein the front layer includes front parts, in which front layer wrap threads and weft threads are basically woven, and first to third front layer-connecting parts, in which front layer wrap threads and wrap threads and weft threads forming the light-shielding layer are woven, which are sequentially and repeatedly formed, 
 wherein the rear layer includes rear parts, in which rear layer wrap threads and weft threads are basically woven, and first to third rear layer-connecting parts, in which the rear layer wrap threads and wrap threads and weft threads forming the light-shielding layer are woven, which are sequentially and repeatedly formed, 
 wherein the first to the third light-shielding layers are formed by weaving the wrap threads and the weft threads forming the light-shielding layer, 
 wherein the first to third light-shielding layers are connected to the first to third front layer-connecting parts and the first to third rear layer-connecting parts sequentially and repeatedly, 
 wherein the third rear layer-connecting parts are disposed on the rear layer facing the first front layer-connecting part on the front layer, 
 wherein the first rear layer-connecting part is disposed on the rear layer facing the second front layer-connecting part on the front layer, 
 wherein the second rear layer-connecting part is disposed on the rear layer facing the third front layer-connecting part on the front layer, 
 wherein the first to the third rear layer-connecting parts are longer than the first to the third front layer-connecting parts and shorter than distances between the first to the third front layer-connecting parts, and 
 wherein the light-shielding layer connected to the respective rear layer-connecting parts is overlapped with another light-shielding layer connected and adjacent to a front layer-connecting part directly above a next rear layer connecting part. 
 
     
     
       2. The three-dimensional woven fabric as claimed in  claim 1 , wherein the wrap threads forming the light-shielding layer are produced without crossing with the weft threads on the front side of the front parts and are exposed to the outside, and
 the exposed wrap threads are sheared after weaving. 
 
     
     
       3. The three-dimensional woven fabric as claimed in  claim 1 , wherein the light-shielding layers have a half light-transmittable structure. 
     
     
       4. The three-dimensional woven fabric as claimed in  claim 1 , wherein the first to the third rear layer-connecting parts are formed by weaving the first to the third light-shielding layer wrap threads with the rear layer wrap threads and the rear layer weft threads such that initial portions of the first to the third rear layer-connecting parts are woven densely by a preset length and the rests thereof are woven intermittently. 
     
     
       5. A method of producing a three-dimensional woven fabric comprising a front layer, a rear layer, and a light-shielding layer connecting the front layer to the rear layer, the method comprising:
 weaving front layer weft threads to front layer wrap threads to form the front layer; and 
 connecting first light-shielding layers, second light-shielding layers, and third light-shielding layers, which have light-shielding wrap threads and light-shielding weft threads, to the front layer and the rear layer sequentially and repeatedly while the rear layer weft threads are woven to the rear layer wrap threads to form the rear layer in the state of being spaced apart by a preset distance from the front layer to be parallel thereto; 
 wherein the first light-shielding layer wrap threads of the first light-shielding layer repeat a process of forming first front layer-connecting parts in association with the front layer wrap threads and the front layer weft threads, being exposed out of the front part up to the starting points of the second front layer-connecting parts without crossing with weft threads, passing through the third light-shielding layer and crossing to the rear layer to form the first rear layer-connecting parts in association with the rear layer wrap threads and the rear layer weft threads, being woven to the light-shielding layer filings to form the first light-shielding layers, and forming the first front layer-connecting parts at the next position; 
 wherein the second light-shielding layer wrap threads of the second light-shielding layer repeat a process of forming the second front layer-connecting parts in association with the front layer wrap threads and the front layer weft threads, being exposed out of the front part up to starting points of the third front layer-connecting parts without crossing with weft threads, passing through the first light-shielding layers and crossing to the rear layer to form the second rear layer-connecting parts in association with the rear layer wrap threads and the rear layer weft threads, being woven to the light-shielding layer weft threads to form the second light-shielding layers, and forming the second front layer-connecting parts at the next position; 
 wherein the third light-shielding layer wrap threads of the third light-shielding layer repeat a process of forming the third front layer-connecting parts in association with the front layer wrap threads and the front layer weft threads, being exposed out of the front part up to starting points of the first front layer-connecting parts without crossing with weft threads, passing through the second light-shielding layers and crossing to the rear layer to form the third rear layer-connecting parts in association with the rear layer wrap threads and the rear layer weft threads, being woven to the light-shielding layer weft threads to form the third light-shielding layers, and forming the third front layer-connecting parts at the next position; and 
 wherein the first to the third light-shielding layer wrap threads exposed out of the front layer are removed after weaving. 
 
     
     
       6. A method of producing a three-dimensional woven fabric comprising a front layer, a rear layer, and a light-shielding layer connecting the front layer to the rear layer, the method comprising:
 weaving a front part and a rear part by healds Nos. 1/2 and 3/4 respectively, first, second and third connecting parts of the front layer by healds Nos. 1/2/5/6, 1/2/7/8, and 1/2/9/10 respectively, and first to third connecting parts of the rear layer by heald frame Nos. 3/4/5/6, 3/4/7/8, and 3/4/9/10 respectively, wherein wrap threads of the front layer are expressed by the healds Nos. 1/2, wrap threads of the rear layer are expressed by the healds Nos. 3/4, first light-shielding layer wrap threads are expressed by the healds Nos. 5/6, second light-shielding layer wrap threads are expressed by the healds Nos. 7/8, and third light-shielding layer wrap threads are expressed by the heald frame Nos. 9/10; 
 wherein the front part in which front layer wrap threads and front layer weft threads are woven and first to third front layer-connecting parts, in which the front layer wrap threads and wrap threads and weft threads forming the light-shielding layer are woven, are sequentially and repeatedly formed on the front layer; 
 wherein rear parts, in which rear layer wrap threads and weft threads are woven, and first to third rear layer-connecting parts, in which the rear layer wrap threads and the wrap threads and weft threads forming the light-shielding layer are woven, are sequentially and repeatedly formed on the rear layer; 
 wherein the first to the third light-shielding layers formed by the wrap threads and weft threads forming the light-shielding layer, are sequentially and repeatedly connected to the front layer and the rear layer; and 
 wherein the light-shielding wrap threads exposed to the outside of the front parts during the weaving are removed by shearing after weaving; 
 wherein the third rear layer-connecting parts are disposed on the rear layer facing the first front layer-connecting part on the front layer, 
 wherein the first rear layer-connecting part is disposed on the rear layer facing the second front layer-connecting part on the front layer, 
 wherein the second rear layer-connecting part is disposed on the rear layer facing the third front layer-connecting part on the front layer, 
 wherein the first to the third rear layer-connecting parts are longer than the first to the third front layer-connecting parts and shorter than distances between the first to the third front layer-connecting parts. 
 
     
     
       7. The three-dimensional woven fabric as claimed in  claim 2 , wherein the light-shielding layers have a half light-transmittable structure. 
     
     
       8. The three-dimensional woven fabric as claimed in  claim 2 , wherein the first to the third rear layer-connecting parts are formed by weaving the first to the third light-shielding layer wrap threads with the rear layer wrap threads and the rear layer weft threads such that initial portions of the first to the third rear layer-connecting parts are woven densely by a preset length and the rests thereof are woven intermittently.